Pulp-molded container structure and molding device and method thereof

ABSTRACT

The present invention relates to a pulp-molded container structure and molding device and method thereof. The molding device comprises a first container molding die and a second container molding die. The first container molding die comprises a snap-fit molding part and a rim molding part, so that a snap-fit section of the pulp-molded container structure and a circular rim section at the edge of the pulp-molded container structure are formed when the first container molding die and the second container molding die are coupled with each other. The rim section and the snap-fit section are used to strengthen the combination of the pulp-molded container structure and an external container, so that the combination is more stable.

INCORPORATION BY REFERENCE

The present application is a continuation in part of U.S. patent application Ser. No. 15/595,893 filed on May 15, 2017 which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present disclosure relates to a pulp-molded container structure, particularly a pulp-molded container structure and a molding device thereof wherein the pulp-molded container structure comprises a snap-fit section which is formed with the pulp-molded container structure integrally and coupled with a cup.

2. Description of the Prior Art

Paper cups and bowls are disposable consumables ubiquitous in our daily lives. Currently, the manufacturers considering costs of manufacturing materials and requests for distinct products have created various methods to manufacture these disposable consumables.

To manufacture a paper product with firm texture or styling or a thicker layer, a manufacturer should deposit paper pulp to a certain thickness for molding. However, the convex edges or irregular surface wrinkles, which are extruded from deposited paper pulp frequently and disfigures the aesthetic exteriors or structural strength, are common in ordinary thinner disposable paper cups or bowls made of thicker paper pulp and shaped in the conventional manufacturing process.

Furthermore, an appropriate manufacturing process based on pulp molding (also known as the pulp die molding method) developed recently is applicable to paper products with a certain thickness. However, the inside embossed or barb-like patterns which contribute to securing combination of a cup container and a paper cup are mostly disposed on the rim and/or the snap-fit section of an ordinary pulp-molded cup container and shaped on a formed container in a secondary local roll-extrusion process.

In this regard, the time cost in a secondary roll-extrusion process for rework which probably causes defects or disfigurements is indispensable to in-process containers.

SUMMARY OF THE INVENTION

To resolve the problems in the prior arts, an integrated pulp-molded container structure provided in the present disclosure is to reduce manufacturing time and costs.

According to the purpose, a pulp-molded container structure comprises a central section and a rim section which encircles the central section, accommodates an upper wall edge of an external container coupled with the pulp-molded container structure, and clamps the wall edge of the external container.

Furthermore, the rim section comprises a snap-fit section, which is downward connected with the upper wall edge of the external container, manufactured with the central section as well as the rim section integrally, and further coupled with a protrusion encircling the external container for a firm combination of the pulp-molded container structure and the external container when the rim section clamps the upper wall edge of the external container.

To manufacture the pulp-molded container structure, the present disclosure provides a molding device of a pulp-molded container structure, which comprises a first container molding die and a second container molding die, wherein the first container molding die comprises a first molding unit with a center molding part for shaping of the corresponding central section of the pulp-molded container structure and a rim molding part for shaping of the corresponding rim section of the pulp-molded container structure; the rim molding part comprises a snap-fit molding part recessed from an outer edge of the rim molding part and situated at one side far away from the center molding part for shaping of the minus degree snap-fit section of the pulp-molded container structure; the second container molding die comprises a second molding unit for shaping of a corresponding exterior profile of the pulp-molded container structure.

To manufacture the pulp-molded container structure, the present disclosure further provides a molding method of a pulp-molded container structure, which comprises immersing a first container pulp-sucking and molding die in a pulp slurry, and draining and pressing the pulp slurry to shape a raw container; then removing the raw container to a first container heating and molding die, and heating and sealing the raw container between the first container heating and molding die and the second container heating and molding die, to shape the pulp-molded container structure.

As mentioned previously, in pulp-based hot press molding steps, the elastic pulp-molded container structure features the snap-fit section which is slightly deformed for separation from the snap-fit molding part in a de-molding process and characteristic of a profile similar to that of the snap-fit molding part. As such, the snap-fit section is coupled with a protrusion extended outward from a cup rim of an external container which is to be connected to the snap-fit section at the pulp-molded container structure as required in standards of product manufacturing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of a pulp-molded of coffee container structure;

FIG. 2 is a sectional view which illustrates both a pulp-molded container structure and an external container join together;

FIG. 3 is a schematic view which illustrates a second container molding die in a molding device of a pulp-molded container structure;

FIG. 4 is a schematic view which illustrates a first container molding die in a molding device of a pulp-molded container structure;

FIG. 5 is a sectional view which illustrates a molding device of a pulp-molded container structure in disengaged status;

FIG. 6 is a sectional view of a container pulp-sucking and molding device for a pulp-molded container structure;

FIG. 7A is the first schematic view which illustrates a molding device of a pulp-molded container structure in a de-molding process;

FIG. 7B is the second schematic view which illustrates a molding device of a pulp-molded container structure in a de-molding process;

FIG. 7C is the third schematic view which illustrates a molding device of a pulp-molded container structure in a de-molding process;

FIG. 8 is a flow diagram for steps in a manufacturing process of using a molding device of a pulp-molded container structure;

FIG. 9 is a schematic view of a container pulp-sucking and molding device for a pulp-molded container structure in another embodiment;

FIG. 10 is a schematic view which illustrates a molding device of a pulp-molded container structure in a molding process in another embodiment;

FIG. 11 is a sectional view of a pulp-molded of bowl container structure; and

FIG. 12 is a sectional view of a pulp-molded of box container structure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The features, content, advantages and effects of a pulp-mold container and a molding device thereof in the present disclosure are explained in embodiments and accompanying drawings which are schematic views to illustrate the patent specification but not intended to limit the scope of patent claims.

Referring to FIG. 1 which is a sectional view of a pulp-molded container structure 1 comprising a central section 10 and a rim section 12 encircling the central section 10 and having a sidewall and a top edge part for development of an inverted U-shaped profile and further an annular snap-fit section 14 at an inner surface of the rim section 12 being far away from the sidewall of the central section 10 and protruding inwardly in minus degree.

Referring to FIG. 2, which illustrates the pulp-molded container structure 1 easily connected and coupled with an external container 3 by means of the rim section 12 clamps the entire upper edge of an exterior wall of the external container 3 preferably. As shown in FIG. 2, the snap-fit section 14 abuts and contacts a protrusion 300 outward raised or rolled from the upper edge of an exterior wall of the external container 3, contributing to a better combination of the pulp-molded container structure 1 and the external container 3. It can be seen that either the rim section 12 or the snap-fit section 14 is designed to secure the pulp-molded container structure 1 and the external container 3 as required in standards of product manufacturing.

As a pulp-molded container structure of an ordinary paper cup in which coffee is carried in the daily life, the pulp-molded container structure 1 in FIG. 1 comprises the circular central section 10 with a convex part raised from the edge and a concave part at the center of the central section 10 in an embodiment; the central section 10 comprises an opening from which beverages inside are drawn and a perforation drilled on the concave part to balance pressure in a container filled with beverages. However, it should be iterated that the opening or the perforation is not a primary technical feature for a pulp-molded container structure herein.

Referring to FIGS. 3 to 5, which illustrate a molding device of a pulp-molded container structure comprises a first container molding die 22 and a second container molding die 20. The first container molding die 22 comprises a first molding unit 220 with a center molding part 2201 and a rim molding part 2202 wherein the center molding part 2201 and the rim molding part 2202 are used in shaping an interior profile of the central section 10 of the pulp-molded container structure 1 and an interior profile of the rim section 12 of the pulp-molded container structure 1, respectively. Moreover, the first container molding die 22 comprises a snap-fit molding part 2203 which is designed on the rim molding part 2202 for shaping of the rim section 12 and at one side far away from the central section 10 and used to form the snap-fit section 14 of the pulp-molded container structure 1; the second container molding die 20 comprises a second molding unit 200 designed at one side and used in shaping an exterior profile of the pulp-molded container structure 1, wherein the rim section 12 is used to clamp an outside wall of the external container 3 which is coupled with the pulp-molded container structure 1.

Referring to FIG. 6, which illustrates a strainer 226 is installed on the first molding unit 220 of the first container molding die 22 and a plurality of pore channels 2204 are uniformly distributed on the first container molding die 22 for development of a first container pulp-sucking and molding die used in a practical process. In an embodiment of a pulp-molded container structure, each of the pore channels 2204 is opened on an outer edge of the rim molding part 2202 of the first molding unit 220, between the center molding part 2201 and the rim molding part 2202, and the topmost end of the center molding part 2201. As such, the strainer 226 lowered into a pulp tank makes paper pulp subside in a first container pulp-sucking and molding die 22A for no pulp fibers getting across the strainer 226 and each of pore channels 2204 from which external air is inhaled provides suction to absorb pulp fibers (preferably, the pulp-molded container structure 1 consists of 5% to 55% of Filament, and 45% to 65% of Spun), draining excessive water without jams of the pore channels 2204 and shaping a raw pulp-molded container structure 1 inside the first container pulp-sucking and molding die 22A. Furthermore, a plurality of pore channels 2021 are opened on the second molding unit 200 of the second container molding die 20 for development of a second container pulp-sucking and molding die 20A. In the embodiment, each of the pore channels 2021 is further opened on an outer edge of the second molding unit 200 and opposite to the center molding part 2201 as well as the rim molding part 2202 of the first molding unit 220. As such, the second container pulp-sucking and molding die 20A and the first container pulp-sucking and molding die 22A are coupled with each other for supply of suction induced by outward exhaled air to the pore channels 2021 through which a raw pulp-molded container structure is sucked by the second container pulp-sucking and molding die 20A from the first container pulp-sucking and molding die 22A.

Furthermore, when the first container molding die 22 is excavated for placement of a heating rod and a thermocouple, or the first container molding die 22 is made with thermal conductive materials and is securely installed on a heating plate in the embodiment, a first container heating and molding die, which is heated directly or via thermal conduction to increase temperature of the first molding unit 220 inside and dry paper pulp, is created; on the other hand, when the second container molding die 20 is excavated for placement of a heating rod and a thermocouple, or the second container molding die 20 is made with thermal conductive materials, and is securely installed on another heating plate, a second container heating and molding die, which is heated directly or via thermal conduction to increase temperature of the second molding unit 200 inside and dry paper pulp, is created and comprises a plurality of pore channels 2021 through which the dried pulp-molded container structure 1 is sucked. It should be iterated that neither the first molding unit 220 in the first container molding die 22 nor the second molding unit 200 in the second container molding die 20 are provided with a strainer 226 inside.

But if the first container molding die 22 and the second container molding die 20 are applied on a plastic container manufacturing process, the pore channels (2021, 2204) on the first and second container molding die (20, 22), and the strainer 226 will be no more needed, due to the pore channels (2021, 2204) are arranged for providing suction to absorb pulp fibers when external air is inhaled, and the strainer 226 is installed for isolating pulp fibers, to make no pulp fibers get across the strainer 226. In the case of above, the plastic container has no fibers to allow the strainer 226 isolating or the pore channels (2021, 2204) absorbing, therefore, the first container molding die 22 and the second container molding die 20 cannot be utilized on the plastic container manufacturing process.

Referring to FIGS. 7A, 7B and 7C, which are schematic views illustrating a molding device of a pulp-molded container structure in a de-molding process. A pulp-molded container structure is sucked by the corresponding second container pulp-sucking and molding die 20A and removed from the first container pulp-sucking and molding die 22A in a continuous process, as shown in schematic partial enlargement views which present a relationship between the snap-fit molding part 2203 at the edge of the first container molding die 22 or the first container pulp-sucking and molding die 22A and the pulp-molded container structure 1.

Referring to FIG. 7A in which there is no second container pulp-sucking and molding die displayed. FIG. 7A illustrates status before a de-molding process that the raw pulp-molded container structure 1 shaped in a pulp molding process is securely attached to and matches the profile of the snap-fit molding part 2203 at the edge of the first container molding die 22 through the strainer 226 and the snap-fit section 14 of the pulp-molded container structure 1 totally fits into the strainer 226.

Referring to FIG. 7B, which illustrates the raw pulp-molded container structure 1 shaped in a pulp molding process is sucked by the second container pulp-sucking and molding die 20A and gradually separated from the first container molding die 22 in the first container pulp-sucking and molding die 22A as well as the attached strainer 226. As shown in FIG. 7B, the snap-fit section 14 of the pulp-molded container structure 1, which is made of extensible paper and extended a bit, is being removed from but still squeezed by the snap-fit molding part 2203 and slightly deformed in a de-molding process of separating a die from the other upward.

Referring to FIG. 7C, which illustrates the raw pulp-molded container structure 1 shaped in a pulp molding process is sucked by the second container pulp-sucking and molding die 20A and totally separated from the first container molding die 22 as well as the attached strainer 226. As shown in FIG. 7C, the extensible paper snap-fit section 14 of the pulp-molded container structure 1, which was totally separated from the first container pulp-sucking and molding die 22A and deformed partially, is slightly reconstituted and overall matches the profile of the snap-fit molding part 2203 as appropriate but possibly leaves some distinct squeezed and deformed or truncated parts which have no adverse effect on a pulp-molded container structure with a manufacturing process corrected for better fastening strength between the snap-fit section 14 and a convex part of an external container 3.

Referring to FIG. 8, which illustrates a flow diagram for a manufacturing process of using a molding device of a pulp-molded container structure to shape a pulp-molded container structure according to steps as follows:

Step S801: the first molding unit is covered with pulp slurry when the first container pulp-sucking and molding die is immersed in pulp slurry.

Step S802: the first container pulp-sucking and molding die is removed from pulp slurry and excessive water, which is included in pulp slurry deposited on the first molding unit and unused in a manufacturing process, is drained from the pore channels and the strainer.

Step S803: the second container pulp-sucking and molding die is driven to fit into the first container pulp-sucking and molding die so that a raw container featuring a profile similar to that of a desired pulp-molded container structure is shaped with dehydrated paper pulp adhered to and matching the strainer on the first molding unit.

Step S804: the raw container is sucked by the second container pulp-sucking and molding die through the pore channels for separation from the first container pulp-sucking and molding die in a de-molding process.

Step S805: the raw container is held in the first container heating and molding die with which the second container pulp-sucking and molding die is coupled.

Step S806: the second container heating and molding die is driven to fit into the first container heating and molding die completely for sealing the raw container between the first and second container heating and molding dies.

Step S807: the raw container is heated and dried by the first container heating and molding die as well as the second container heating and molding die and totally dehydrated for shaping of the pulp-molded container structure.

Step S808: the pulp-molded container structure is sucked by the second container heating and molding die for separation.

According to a manufacturing process from step S801 to step S808, a pulp-molded container structure is shaped. Particularly, shaping 500 kg/m³ to 700 kg/m³ density, and 0.5 mm to 1.2 mm thickness of the pulp-molded container structure.

An alternative manufacturing process different from that of the above embodiment is introduced in the present disclosure. In the alternative embodiment, the profile of a first molding unit (a second molding unit) in a container pulp-sucking and molding die (as well as a container heating and molding die) is exchanged to the profile of a second molding unit (a first molding unit). When a molding unit to shape an exterior profile of a pulp-molded container structure is first immersed in pulp slurry and driven to fit into another molding unit which is used to shape an interior profile of a snap-fit section on the pulp-molded container structure, a pulp-molded container structure featuring an identical profile can be created with two dies at reversed positions.

Referring to FIGS. 9 and 10, which illustrate an another embodiment of the first container molding die 22 and the second container molding die 20, as shown in the FIG. 9, the first container molding die 22 and the second container molding die 20 can be arranged on opposite position (which means the first container molding die 22 arranged on upside, and the second container molding die 20 arranged on bottom-side).

After the second container molding die 20 immersed in pulp slurry, the second molding unit 200 is covered with pulp slurry, and by the way of draining the pulp slurry by the pore channels 2021 and the strainer on the second container molding die 20, driving the first container molding die 22 to fit into the second container molding die 20 to shape the desired pulp-molded container structure with dehydrated paper pulp, and absorbing the raw container by the first container molding die 22 to process a de-molding process and heating process etc. thus, the pulp-molded container structure 1 and the snap-fit 14 can be also shaped through afore-molding-process.

Referring to FIGS. 11 and 12, which are sectional views illustrating another embodiments of the pulp-molded container structure 1, and please refer the FIG. 1 together. In alternative embodiments, the pulp-molded container structure 1 in the present invention can further be utilized on bowl container, box container, or any similar kinds.

In the one of embodiment (e.g. bowl container), the snap-fit 14 is formed on the inner surface of the annular rim section 12 of the bowl container 1, for engaging with the protrusion 300 on the peripheral of the bowl 3.

The another embodiment (e.g. box container) is similar with the bowl container embodiment of above, the snap-fit 14 can be also formed on the inner surface of the annular rim section 12 of the box container 1, for engaging with the protrusion 300 on the peripheral of the box 3.

Therefore, the pulp-molded container structure 1 in the present invention can be utilized for various containers, but is not limited in the aforementioned embodiments.

In summary, a pulp-molded container structure and a molding device thereof for once-and-for-all die molding of a snap-fit section in the patent application, which are innovative work in technical ideas and features several effects in contrast to conventional molded containers, meets novelty and non-obviousness for patentability. 

What is claimed is:
 1. A molding device of a pulp-molded container structure for manufacturing of the pulp-molded container structure comprises: a first container molding die comprising a first molding unit for shaping of a complete interior profile of the pulp-molded container structure, wherein the first molding unit has a center molding part for shaping of the central section of the pulp-molded container structure and a rim molding part for shaping of the rim section of the pulp-molded container structure and the rim molding part has an annular snap-fit molding part situated at an outer edge and at one side far away from the center molding part for shaping of the snap-fit section of the pulp-molded container structure; and a second container molding die, comprising a second molding unit for shaping of a complete exterior profile of the pulp-molded container structure and being driven to fit into the first container molding die for shaping of the pulp-molded container structure in 0.5 mm to 1.2 mm thickness between the second container molding die and the first container molding die.
 2. The molding device of a pulp-molded container structure of claim 1, wherein the first molding unit optionally comprises a plurality of pore channels penetrating the first molding unit inside and each of the pore channels creating suction during shaping of the pulp-molded container structure, for draining excessive water in pulp slurry, or regulating pressure in a pulp molding process.
 3. The molding device of a pulp-molded container structure of claim 1, wherein the second molding unit optionally comprises a plurality of pore channels penetrating the second molding unit inside and each of the pore channels being used to regulate pressure during shaping of the pulp-molded container structure or create suction by the pulp-molded container structure being sucked and separated from the first container molding die.
 4. The molding device of a pulp-molded container structure of claim 1, wherein the first container molding die is provided with a strainer adhered to the first molding unit and immersed in paper pulp for construction of a first container pulp-sucking and molding die and the strainer comprises a plurality of fine meshes to filter paper pulp and keep pulp fibers attached and paper pulp deposited on the first container pulp-sucking and molding die, covered over the first molding unit, and correspondingly applied to the second container molding die for shaping of the pulp-molded container structure by the second molding unit in a second container pulp-sucking and molding die.
 5. The molding device of a pulp-molded container structure of claim 1, wherein the second container molding die is made with thermally conductive materials for heating and drying paper pulp and shaping the pulp-molded container structure; and the first container molding die is made with thermal conductive materials for heating and drying paper pulp and shaping the pulp-molded container structure.
 6. A molding device of a pulp-molded container structure for manufacturing of the pulp-molded container structure comprises: a first container molding die comprising a first molding unit for shaping of a complete exterior profile of the pulp-molded container structure; a second container molding die comprising a second molding unit for shaping of a complete interior profile of the pulp-molded container structure, wherein the second molding unit has a center molding part for shaping of the central section of the pulp-molded container structure and a rim molding part for shaping of the rim section of the pulp-molded container structure, and the rim molding part has an annular snap-fit molding part situated at an outer edge and one side far away from the center molding part for shaping of the snap-fit section of the pulp-molded container structure; wherein the second container molding die and the first container molding die are coupled with each other for shaping of the pulp-molded container structure in 0.5 mm to 1.2 mm thickness with paper pulp held between the second container molding die and the first container molding die.
 7. The molding device of a pulp-molded container structure of claim 6, wherein the first molding unit optionally comprises a plurality of pore channels penetrating the first molding unit inside and each of the pore channels creating suction during shaping of the pulp-molded container structure, for draining excessive water in pulp slurry, or regulating pressure in a pulp molding process.
 8. The molding device of a pulp-molded container structure of claim 6, wherein the second molding unit optionally comprises a plurality of pore channels penetrating the second molding unit inside and each of the pore channels being used to regulate pressure during shaping of the pulp-molded container structure or create suction by which the pulp-molded container structure being sucked and separated from the first container molding die.
 9. The molding device of a pulp-molded container structure of claim 6, wherein the first container molding die is provided with a strainer adhered to the first molding unit and immersed in paper pulp for construction of a first container pulp-sucking and molding die and the strainer comprises a plurality of fine meshes to filter paper pulp and keep pulp fibers attached and paper pulp deposited on the first container pulp-sucking and molding die, covered over the first molding unit, and correspondingly applied to the second container molding die for shaping the pulp-molded container structure by the second molding unit in a second container pulp-sucking and molding die.
 10. The molding device of a pulp-molded container structure of claim 6, wherein the second container molding die is made with thermal conductive materials for heating and drying paper pulp and shaping the pulp-molded container structure; and the first container molding die is made with thermal conductive materials for heating and drying paper pulp and shaping the pulp-molded container structure.
 11. A molding method of a pulp-molded container structure for manufacturing of the pulp-molded container structure comprises: covering with a pulp slurry on a first molding unit, when a first container pulp-sucking and a molding die being immersed in the pulp slurry; removing the first container pulp-sucking and the molding die from a pulp slurry; removing excessive water on the first molding unit by draining from a plurality pore channels and a strainer; shaping a raw container structure by a second container pulp-sucking and molding die fitting with a first container pulp-sucking and molding die; sucking the raw container by the second container pulp-sucking and molding die, to remove the raw container from the first container pulp-sucking and molding die; holding the raw container by a first container heating and molding die; sealing the raw container in between the first container heating and molding die and a second container heating and molding die; heating and drying the raw container by the first container heating and molding die and the second container heating and molding die, to shape a pulp-molded container structure.
 12. The molding method of a pulp-molded container structure of claim 11, wherein the raw container is shaped with dehydrated paper pulp adhered to and matching the strainer on the first molding unit.
 13. The molding method of a pulp-molded container structure of claim 11, wherein the second container pulp-sucking and molding die sucks the raw container through the pore channels.
 14. The molding method of a pulp-molded container structure of claim 11, wherein a central section, a rim section, and an annular snap-fit section are formed at the same time on the pulp-molded container when the pulp-molded container is shaped by the first container heating and molding die and the second container heating and molding die.
 15. The molding method of a pulp-molded container structure of claim 11, further comprises: sucking the pulp-molded container structure by the second container heating and molding die, to separate the pulp-molded container structure from the second container heating and molding die.
 16. A pulp-molded container structure is made by the molding device of claim 1 or 6, wherein the container structure comprises: a central section at the center and an annular rim section encircling the central section and having a sidewall; a snap-fit section extended from the outside of the sidewall, protruding inwardly in minus degree, and formed integrally with the pulp-molded container structure, and expanded and contracted based on physical elasticity of paper pulp for abutting and fastening a protrusion extended from a rim of an external container that is coupled with the pulp-molded container structure.
 17. The pulp-molded container structure of claim 16, wherein the rim section is used to clamp an outside wall of the external container which is coupled with the pulp-molded container structure.
 18. The pulp-molded container structure of claim 16, wherein the container structure consists of 5% to 55% of Filament, and 45% to 65% of Spun.
 19. The pulp-molded container structure of claim 16, wherein the density of the container structure is between 500 kg/m³ to 700 kg/m³.
 20. The pulp-molded container structure of claim 16, wherein the thickness of the container structure is between 0.5 mm to 1.2 mm. 